Plant for manufacturing reinforced concrete construction panels

ABSTRACT

A plant for manufacturing reinforced concrete construction panels including at least one bank of moulds comprising a plurality of generally vertical partitions and electrically heated forms. At least some of the partitions and forms are mounted by rollers on tracks for displacement perpendicular to the major faces of the moulds. Once a mould has been poured and the panel therein hardened, the movable one of its walls is horizontally displaced from the rest of the panel and mould combination. The panel may then be removed by a lifting device. After being cleaned the movable mould wall is moved back into its initial position where it is connected to another form or partition which itself is disconnected from its adjacent form or partition freeing a further panel for removal and enabling the pouring of a further panel without any substantial time delay.

United States Patent 1 Camus [451 Apr. 16, 1974 PLANT FOR MANUFACTURING REINFORCED CONCRETE CONSTRUCTION PANELS [76] Inventor: Raymond Francois Emile Camus,

27, Avenue Foch 75, Paris 16, France [22] Filed: Aug. 11, 1971 [211 App]. No.: 170,910

[30] Foreign Application Priority Data Aug. 14, 1970 France 70.30068 July 9, 1971 France 71.25269 [52} US. Cl ..-249/78, 249/120, 249/161 [51] Int. Cl 1328b 7/22 [58] Field of Search 249/120, 78, 161

[56] References Cited UNITED STATES PATENTS 3,488,817 1/1970 Katz 249 120 x 1,760,282 5/1930 Pederson 249/129 X 3,075,240 H1963 Casavina 249/120 X FOREIGN PATENTS OR APPLICATIONS 518,525 3/1955 ltaly 249/120 Primary Examiner-Robert D. Baldwin Assistant ExaminerJohn McQuade Attorney, Agent, or Firm-Eric H. Waters A plant for manufacturing reinforced concrete construction panels including at least one bank of moulds comprising a plurality of generally vertical partitions and electrically heated forms. At least some of the partitions and forms are mounted by rollers on tracks for displacement perpendicular to the major faces of the moulds. Once a mould has been poured and the panel therein hardened, the movable one of its walls is horizontally displaced from the rest of the panel and mould combination. The panel may then be removed by a lifting device. Afterbeing cleaned the movable mould wall is moved back into its initial position where it is connected to another form or partition which itself is disconnected from its adjacent form or partition freeing a further panel for removal and enabling the pouring of a further paznel without any substantial time delay.

ABSTRACT 3 Claims, 11 Drawing Figures PATENTEDAPR 16 I874 SHEET 1 (IF 7 MWII,

mm m 02 8 mm 2 S 2 3 mm mm mm 2: av s E PLANT FOR MANUFACTURING REINFORCED CONCRETE CONSTRUCTION PANELS The present invention relates to a plant for the manufacture of concrete construction panels by formwork.

For the manufacture of concrete construction panels an apparatus is used which comprises a plurality of vertical partitions, or forms between which the aggregate is poured possibly after the arrangement of cores or the like in the forming mould and left until sufficient hardening of the concrete, the panels being then removed from the apparatus by means of a travelling crane.

In order to speed up the setting of the concrete, it has been proposed to heat the same, preferably by means of electric current flowing through resistance heaters incorporated in a wall of the mould.

In the operation of apparatus for the manufacture of concrete construction panels, the most efficient use of the manpower available as well as the manufacture with a predetermined amount of manpower during a work day for the maximum number of construction panels is a difficult probelm to solve.

According to the present invention, a plant for manufacturing concrete construction panels by formwork comprises forms, certain of which advantageously include electric heating means, displaceably mounted alone or in a group, in a direction perpendicular to it or their planes thereby enabling the release of hardened panels and their removal immediately after hardening.

In a plant according to the invention, the manufacture of various panels is effected in succession in the various pouring spaces allowing non interrupted preparation of the moulds after removal of a panel and thus an optimum use of the manpower. The invention also concerns a form enabling the rapid removal of reinforced concrete panels poured in a bank of formwork so as to increase the yield.

In known plants the reinforced concrete panels poured in the spaces between successive forms are removed therefrom with the aid of suspension slings embedded in the concrete.

Such a removal is only possible if the slings embedded in the concrete sufficiently resist being pulled out.

Therefore, it is generally necessary to wait a certain amount of time so that the setting of the concrete provides a sufficient resistance to the pulling force.

It is known that this time can be reduced by the heating or baking of the concrete effected by heating forms which advantageously comprises electrical resistors, the said heating forms being distributed throughout the thickness of a bank of formwork comprising a number of smaller or larger pouring spaces.

It is also known that such a formwork bank may comprise movable forms mounted on rollers and capable of displacement by double-action jacks in order to facilitate the removal and replacement of the bank.

But in all these plants the time gained is limited by the fact that one must wait for sufficient setting of the concrete in order to remove the panels from the moulds and hence the preparatory work in the spaces for a subsequent pourings may only be effected after the removal of the panels.

The plant according to the invention overcomes these drawbacks by enabling the rapid removal of the cast panels from each side of a form carrier owing to the fact that the form itself is lifted up and not the panels which remain fixed to the form by the peripheral frames which are fixed thereto.

It thus becomes possible to introduce a form carrier previously equipped with form reinforcements and other inserts into the free gap or space in the formwork bank, close the formwork bank and proceed with another pouring without losing any time.

The device according to the invention comprises a central plate, interior and peripheral form members corresponding to the panel being temporarily or permanently fixed to each face of said plate.

The peripheral form members for the panel comprise in general a lower horizontal section, two vertical sections along the sides, the fourth horizontal side at the upper end remaining free for filling.

The central plate comprises at its upper end lifting means, preferably lifting links.

The sides are adapted to receive vibrators.

The lower portion of the central plate is arranged in such a way that it may rest on supports provided for this effect either in the formwork or outside of the formwork bank and may possibly be displaced on rollers in a plane along the ground.

When the form carrier device according to the invention is placed in a formwork bank between two forms which, owing to the characteristics of the form carrier may be smooth, comprising no coffering, and the forms are brought together and fixedly maintained relative to one another, it is possible to proceed with the pouring of the concrete into the two gaps or spaces located on either side of the central form previously provided with reinforcements and various inserts desired for the panel to be produced.

As soon as the concrete is sufficiently set, it is possible to move away a first smooth-faced form, then lift the form carrier with its two panels maintained by their forms and possibly by a co'operating holding device provided at the upper portion of the central plate.

The form carrier is then removed from a formwork bank and placed where the concrete may age sufficiently for, subsequent removal of the panels by their lifting slings.

As soon as the form carrier with its panels are removed, it is possible to introduce in its place in the formwork bank another form carrier suitably equipped, reclose the formwork bank and proceed with another pouringv In the description which follows, given by way of example, reference is made to the accompanying drawings, in which:

FIG. 1 is a schematic side view in elevation of a plant according to the invention in the moulding position;

FIG. 2 is a schematic top view;

FIG. 3 is an elevation taken at from that of FIG.

FIG. 4 is a front view of a heating form with certain elements removed;

FIG. 5 is a sectional view taken along the line 5-5 of FIG. 4;

FIG. 6 is a horizontal sectional view on a larger scale of an end heating form;

FIG. 7 is a horizontal sectional view on a smaller scale of an intermediary form;

FIG. 8 is a front view partial cut away of a portion of an intermediary form;

FIG. 9 is a vertical sectional view of a portion of an intermediary form;

FIG. 10 is a schematic elevation view of a plant according to another embodiment; and

FIG. 11 is a schematic top view.

The plant comprises a massive and robust end frame 10 (FIGS. 1 and 2) which extends along the entire height and length of the apparatus and supports at its uppermost portion 11 jack bodies 12, 12 and 12 in the present example with movable members 13, 13 13 which are displaceable in a direction perpendicular to the major faces 14 and 15 of the frame structure 10. Similar jacks 12 are provided at the lower portion of the frame structure 10 (FIG. 3).

A hollow end form 16 is joined to the frame structure and comprises support frame members 17, 18 and 19, 20 (FIGS. 4-6) as well as intermediary reinforcing members 21 for maintaining an interior plate 22. The parallelopiped form is thus delimited by the members 17-20, the plate 22 and fittings 23 on the exterior surface, interposed between the frame members.

Inside the form are disposed heating grids 24 comprising snake-shaped resistance heaters 25 with parallel vertical portions 26 (FIG. 4). Reflectors 27 concentrate the heat flux provided by the interior plate 22. The latter is mounted so as to'be freely expandable and contractable by its frictional holding means owing to a flanged member 28 with which it is provided, and through the intermediary of resilient tightening washers 29. Sheets 30 of asbestos are interposed'between the plate 22 and the frame members. A heat insulator 31 such as fibre glass protects the exterior surface and increases the effect of the heating source on the plate 22. Stiffening members 32 are fixed to the plate and their sides are protected by a slab 33 of asbestos.

The resistors within the form 16 are supplied with current through a plug 34 (FIG. 1). A thermostat 35 is provided to cut off the supply of electrical current when the plate 22 reaches a predetermined temperature.

The plate 22 in combination with a plate 41 delimits a first generally parallelopiped pouring space or mould 42. The plate 41 rests by rollers 45 and 46 on tracks 43 or 44.

The plate 41 is detachably connected to the plate 22 by upper and lower latch members 47 and 48 rotatably mounted about vertical pins 49 and 50 which cooperate with pegs 51 and 52 inserted in fittings 53 and 54 fixed to the plate. Such assemblies are present in both sides of the apparatus.

The plate 41 in combination with a plate 55 forming part of an intermediary form 56 provides a second pouring space or mould 57.

The intermediary hollow form 56 is of generally parallelopiped shape and comprises in addition to the plate 55 a parallel plate 58 opposite thereto, the frame including frame members 59 (FIG. 7) and cross members 62. Stiffening members 63 and 64 are provided for the plates 58 and 55. With each box-like portion 65 delimited by plates 55 and 58, and frame members 59 and cross members 62, are disposed heating grids 66 carrying snake-shaped resistance heaters 67. The plates 55 and 58 are connected to the frame members by bolts, as shown at 68. The resistors of the various grids are supplied with current by a junction box or electric socket 69 (FIG. 8). Thermostat(s) 70 are provided to cutt off the supply when the plates reach a predetermined temperature. The stiffening members 63, 64 are protected by strips 71 of asbestos (FIG. 9).

The intermediary form 56 is supported on the tracks 43 and 44 by rollers 72. Latch members 71 and 72' rotatably mounted about pins 49 and 50 enable to releasably connect the intermediary form 56 with a smooth form member or partition 41.

The plate 58 in combination with another plate or partition 74 delimits a third pouring space or mould 75; the plate 74 in combination with its other face and a plate 76 of a second intermediary form 77 delimit a fourth pouring space or mould 78 and so on.

The plate 74 rests by rollers 79 on tracks, and latchs members 81 and 82 enable the releasable connection of the plate 74 with the intermediary form 56.

In the illustrated plant, six panel-manufacturing moulds are provided; a mould 83 on the side of the apparatus opposite that of the mould 42 is delimited by a partition 84 supported by rollers 85 and by a plate 87 of a movable end form 88 whose construction is similar to the form 16 but it is mounted on rollers 89.

A movable element 92 of a jack 93 is attached to a fitting 91 fixed to the form 88, the other end 94 of the jack bears against the foundation.

A gangway 95 is provided which is supported at its end by rollers 96 on tracks.

The operation is as follows:

The position shown in FIGS. l-3 is the panel moulding position. When the concrete in the mould 83 is sufficiently hardened, latch members 97 and 98 which connect the form 88 to the partition 84 are opened and the form 88 is displaced from left to right in FIGS. 1 and 2 by the jack 93. The panel contained in the mould 83, thus having one of its major faces uncovered, can then be easily removed by aid of an over-head crane having hooks which engage hooking members provided on the upper part of the panel.

The removal is advantageously effected by displacement with a horizontal component of the panel such that it is not necessary to have a crane to lift the panel to at least the height of the plant in order to allow the removal of the panel as is required with present plants.

At the extreme right of the of the path of the form 88, the plate 87 may be cleaned, etc.

The movable form 88 is then moved back to its initial position. In this position, the latch members 97 and 98 are reconnected with the form while on the other hand latch members 99 and 100 mounted on the partition 84 are disengaged from the form 77. By a further actuation of the jack 93 for displacing its movable element 92 from left to right, the partition 84 is moved along with the movable form 88, while resting with the partition on the tracks supported by the combination of rollers or wheels 85 and 89. The concrete panel which is sufficiently hardened and which is just uncovered by moving the partition 84 away may be removed in the same manner as was the panel from the mould 83.

By another return movement, the combination of the movable form 88 and the partition 84 is returned towards the form 77. The form is disconnected from the partition 74 by manipulating latch members 101 and 102 and connected again to the partition 84 by the latch members 99 and 100. By another movement in the direction from left to right, the movable form 77 is driven, the rolling unit comprising three pairs of rollers or wheels. The panel from the mould 78 is disengaged and may then be removed, etc.

To the extent that the moulds are re-formed they are cleaned and fitted out so that finally after the panels have been disengaged, the plant is once'again in the close together position, of the various elements, ready to receive a new load of aggregate for the formation of a new series of panels.

After the bringing together of the elements forming the plant, the jacks l2 and 12' are manipulated in a manner as to maintain the elements against one another, the forms thus being in the fixed position required by moulding.

Advantageously two such plants are arranged in proximity of one another and used by the same crew wich works on one plant while the other plant is in its aggregate heating period for quickly hardening the concrete.

Reference will now be made to FIGS. and 11 relative to another embodiment of the invention.

The entire formwork bank is symmetrical with respect to the mean vertical plane of a fixed central frame 120 fixed to two longitudinal beams 121, 122 supporting roller tracks 123, 124.

Fixed frames 125, 126, 127, 128 are located at each end of the longitudinal beams.

In the present example, the formwork bank has eight pouring spaces or moulds 129, 129 Singlefaced electrically heating forms 131,132, i.e., heating on only one of their faces, faces 139, 140 respectively remote from the frame 120, are placed against the fixed central frame, and single-faced heated forms 133 and 134 against movable end forms 135'and 136 provided with rollers 137 and 138 for displacement along the tracks 123 and 124.

Double-faced electrically heating forms 143 and 144 wich heat on both of their faces 145, 146 and 147, 148 respectively are supported on rollers 149 and 150 for movement along the tracks 123 and 124.

The forms 143 and 144 comprise bases 151, 152 respectively adapted to support form carriers 153, 154 respectively.

Single-faced heating forms 131 and l32are also provided with bases, namely 155 and 156 respected adapted to support form carriers 157 and 158.

The. heating forms 131, 132, 133, 134, and 143, 144 are smooth and have no projecting portions.

The double faced heating forms 143 and144 are provided at their upper ends with means (not shown) for temporarily securing to single faced heating forms 131 or 133 and 132 or 134. i

The form carriers 153, 154 and 157, 158, provided with forms- 159-166 and 175-190, and reinforcements, are introduced between heating forms 133 and 143, 143 and 131, 132 and 144, 144 and 134 and rest on the bases 151, 155and 156, 152 provided at the lower end thereof. They includes means for receiving vibrators 191498.

All of these operations are effected on one of the formwork bank halves A and B.

The concrete of the formwork bank half A, for example, before havingsufficient cohesion undergoes the following operations: a

1. The form 143 is disengaged from the form 131 of the frame 120;

2. The hooksof a lifting device are passed through the lifting links 167 of the first form carrier 153;

3. The rolling frame 135 is moved away by means of double action jacks;

4. The form carrier 153 is removed and the panels carried thereby; this unit is placed on a rack;

5. A new form carrier 153 with forms, reinforcements, and various inserts that are prepared in advance is then introduced into the thus liberated base 151;

6. The rolling frame 135 is then moved back into position, the form 143 is then detached from form 131 associated with frame and this same form 143 is then engaged or fixed again to the form 133 associated with the rolling frame 7. The hooks of the lifting device are then passed through the lifting links 170 of the second form carrier 157;

8. The combination comprising the movable frame 135, the form carrier 153' which was just placed, and the double faced heating form 143 are moved away;

9. The second form carrier 157 and the panels carried thereby are removed; this combination is also placed on a rack;

10. A second new form carrier 157' with form members prepared in advance with reinforcements and various inserts is introduced;

11. The combination comprising the movable frame 135, the first new form carrier 153' and the double faced heating form 143 is moved back;

12. The half formwork bank A is maintained in closed position by means of a mechanical device comprisingadjustable sliding rods bearing against fixed end frames 125, 127. i

With the half formwork bank A thus closed, it is possible to proceed with the pouring of the concrete filling the pouring spaces from their upper ends. 1

As soon as the concrete has a sufficent cohesion through the combined action of time and heat given off by the heated forms, it is possible to proceed with a new operating cycle such as the one described above.

During the time necessary to obtain a sufficient cohesion or setting of the concrete in the pouring spaces of the half formwork bank A, the same operations are carried out on the other half formwork bank B.

The device, subject of the present application, may be used in all sorts of heated or non-heating formwork banks.

The use of this device is particularly advantageous when the time for preparing the forms, putting in place the reinforcing members and various inserts, is relatively long.

The easy substitution of the. form carriers between two heating or non-heating forms, which are made common by the fact that they have smooth surfaces, i.e., they do not have to be changed or equipped in spite of the variety of panels to be produced, enables maximum output from the formwork bank in ,a concrete pouring and hardening plant.

The bank according to the invention may be quickly adapted to the casting of panels of different dimensions, particularly with respect of thickness, without any substantial interruption of the normal operating cycle.

While having a certain number of form carriers in reserve wich is not costly since steel plate is involved, present invention enables the easy changing over of the forms for producing different panels while maintaining the high rate of productivity of the plant.

What 1 claim is:

1 Form apparatus for the manufacture of concrete construction panels, said form apparatus comprising a form carrier having opposite surfaces, frame members fixed on both surfaces of said form carrier along the lower and lateral edges thereof, a first heating form on one side of said form carrier, parallel thereto and having a smooth face forming with said form carrier and its associated frame members a first molding chamber open at its top, a second heating form on the opposite side of said form carrier and having a smooth face forming with said form carrier and its associated frame members a second molding chamber also open at its top, means for varying the distance of said heating forms relative to said form carrier, and means, fixed at for displacement thereon of said form carrier. 

1. Form apparatus for the manufacture of concrete construction panels, said form apparatus comprising a form carrier having opposite surfaces, frame members fixed on both surfaces of said form carrier along the lower and lateral edges thereof, a first heating form on one side of said form carrier, parallel thereto and having a smooth face forming with said form carrier and its associated frame members a first molding chamber open at its top, a second heating form on the opposite side of said form carrier and having a smooth face forming with said form carrier and its associated frame members a second molding chamber also open at its top, means for varying the distance of said heating forms relative to said form carrier, and means, fixed at the top of said form carrier for the engagement of hooking means to enable removal of the form carrier together with concrete panels moulded in said moulding chambers.
 2. The form device as defined in claim 1, wherein said heating forms include electrical heating means.
 3. The form device as defined in claim 1, wherein said means for varying the distance of the heating forms relative to said form carrier comprises carriers supporting said first and second heating forms for movement perpendicular to the plane of said heating forms thereto, one of said carriers having a supporting surface for displacement thereon of said form carrier. 